Method of molding duplicate sound-records and other objects.



. J. W. AYLSWORTH. METHOD 0F`MOLD|NG DUPLICATE SOUND RECORDS AND OTHER OB'JECTS'.

v APPUCATION FILED MAY 1909.

1,14638@ Patented 'July 13, 1915.

2 SHEETS-SHEET I.

J. w. AYLSWORTH. METHOD OF MOLDING DUPLICATE SOUND RECORDS AND OTHER OBJECTS.

'1,14638&

APPLICATION FLED MAYI,1909.

Patented July 13, '1915.

2 SHEETS-SHEET 2.

' to a method of molding substances which in osmane ra- GFFXCE JONAS W. AYLSWORTH, OF EAST QRANG-E, NEW JERSEY, ASSIGNOR TO NEW JERSEY PATENT. COMPANY, OF WEST JERSEY. V i

To all whom it may cmcern Be it known that I, J oNAsxlV. YIi S\VORTH,

a citizen of the UnitedStates, and a resident of East Orange, in the county of Essex and State of New Jersey, have made a certain new and useful Invention in Methodsof' Molding y other objects from substances which are not adapted to be moldedrby the' well known' methods.

The invention relates more particularly their final stage are non-plastic at such temperatures as mav be used without injuryto p the substance or the matrix. 4 20;

By means of the method herein described,

(I am enabled to mold sound records, both" cylindrical and disk, from such bodies as are produced when albumenoids and caseins are combined with formaldehyde or other aldeh'yd'es or equivalent substanc'es, and the various non-plastc condensation products of phenols, their homologues, their polymers These bodies have not and derivatives. heretofore been successfully molded nto sound records, but are adapt'ed to form ex cellent sound records if successfully .mol'ded,

becauseof their physical qualities, which are especially useful for the purpose. Hcretofore, sound records or other objects could only be molded from such substances by* Inolding thematerial in the earli'e'r plastic stages of its formation and completing the' reaction of formation in the matrix, whereby a' more -'or less porous and bubbly 'mass resulted, or by molding thefisubstances in a plastic incomplete state and subsequently treating the article with formaldehyde gas i In both cases tle 'esulting product was. not

'or liquid solution .to harden the same.

suitable for sound records because oi air or -gas bubbles and mperfectons of surface which oaused foreign noises when the record thus formed ,was reproduced, and -otherwse impaired the quality of the sound record.

In the present invention, these defects are eliminated and a sound record may be produced which' is most refractory to the wearing action of the 'reproducing stylus, and

Specification of Letters Iatent.

METHOD MOLDING DUPLIAIE SOUND-RECORDS AND OTHER OBJECTS.

lPatented July 13, 1915.

Application filed May I, 1909. Serial No. 493,25s.

specification, and representing apparatus in which my process may be carried out.-

Figure 1 is an elevation, partly in section, of a' suitable rotatable mold in which a cylindrical sound ;recordmay be formed according to the process dsclosed in this applicaton, and Fig. 2 is asimilar View of modified apparatus adaptecl to the same purpose.

' In carryingout theinvention, ingredients such as albumenoids, caseins, gelatins, phenols and their polymers, etc., together with an aldehyde, such as formaldehyde or othei` substance containing the nethylene radical GH may be mixed together with a suitable condensing or catalytic agent andlallowed t'o react with the application of heat to form a liquid or plastic mass, which is then introduced into a matrix such as that shown in either of the figures, in which final reaction by which the non-plastic final product is formed is caused to ensue 'with application of heat while the 'record is being molded.

01" secondly, the body which it is intended to use as thebasis of the substance, such as gelatin or casein mass, may be rendered plastic by waterand heat and "then introduced into the matrix', and formaldehyde or equivalent agent with or .without a catalytic or condensing agent may be subsequently' introduced, either in liquid or, gaseous form into the matrix, and the matrix and its contents heated to hasten the completion of the condensation reaction and the equivalent -polymerization or other' hardening process,

which results in the formation of the final non-plastc product. Or thirdly, a substance in liquid or plastic state may be introduced into the matrix together with a catalytic or other' condensing agent, the substance so produced being-of such a character that polymerization or equivalent hardening action of the substance to a non-plastic permanent state will be induced in the matrix by heat. Asan example of the last mentioned process, a condensation product of phenol with RAlNGEpNEW. JERSEY, A CORPORATION OF NEW I -an aldehyde or other methylene-containng snbstance may be formed by mixing a phenol, as the well known phenol, carbolc acid,

CLOH, with an aldehyde such as tornaldehyde, CLO, in equal molccular proportions and combined by heat and pressure, without the addition, however, ot' a catalytic or condensing agent. The product thns obtained should, to obtain the best results, be evaporated to remove excess ot' tormalde hyde and water at a temperature not exceeding 280 degrees F., and the product obtained is soluble and plastic or may be rendered plastic by beat, and this is combined with a'condensing or catalytic agent, and a small quantity ot a polymerized aldehyde other methylene-containing snbstance such as paratormaldehyde, both preferably in anhydrous condition, and properly mixedf Such a condensing agent may be either an acid or a basic substance. I prefer, however, to use small quantitiesiot acid radicals or substances which will yield a free acid radical, such as pinene hydrochlorid, sublimed aluminium chlorid, stannic chlorid, etc., because of their rapid action. This condensing agent may be added to the mass at a relatively low temperature as by dissolving the mass in a volatile solvent and then adding the condensing agent and paraformaldehyde, 'whereupon the 'product may be poured into the matrix and subjected to subsequent heat treatment while the record is being formed.

In the first and third methods referred to above, a preliminary reaction is caused between the different ingredien'ts before the same are ntroduced into the mold, the final reaction only taking place in the mold during the formation of the record by the molding process, whereas in the second of the' three methods mentioned, the entire reaction between the ingredients takes place in the mold during the formation of the record. In all of these specific methods the final product is formed 'in s'tu in the mold in which the record or other object cast is formed by a 'centrifugal action, the process used being that conmonly known as spmning. a V

.By the method above outlined, the deleterious effects due to porosity because of the setting or hardening or changing from the plastic to the non-plastic state While the mass is evolving gases, may be prevented by the 'pressure exerted on the mass by the` centrifugal action induced by the relatively high speeds at which the matrix is rotated. Sucha process is described and claimed ,in my application No. 493,&16, filed on even date herewith. In the application referred to, the force induced by the centrifugal action alone is depended upon to counteract the tension of dissociation of the mass being `molded so that the formation of gas is pre- 'sealed and the reaction carried out.

method IS applcable n cases m which the ,pla ce thei-ein.

torded by 'the centritugal force ot the rotating mass ot' material at the speedoi rotation which is found desirable, or where it is desirable 'to increase the temperature and thue hasten the reaction without a :further speeding up of the apparatus. This additional p'essure may be obtained in either ot two ways. It may be obtained by :torcing a charge ot compressed tornaldehyde gas or equivalent agent into the mold, which is then ihis tormaldehyde or equivalent agent is introduced in the mold in a gaseous state, as it may be, 'or example, in the second of the three specific methods described above. Or secondly, in cases in which the formaldehyde or equivalent agent is introduced into the matrix in liquid 'orm or into. a liquid or plastic mass in which the formaldehyde or V its equivalent has already been incorporated,

pressure may be obtained by foroing a charge of compressed air into the mold, or by torcing into the mold a charge of any other compressed gas of stich a character that it will not attect the reaction taking allowed to ;take place in an uncovered mold placed in. theipressure chamber in which pressure of the desired amount to reinforce that furnished by the centrifugal action may be developed.

l leferring to the drawings, the mold 1 in .Fig. 1 may be inserted within the rotatable container 2, which is integral with or Secured to the spindle 3, which is adapted to be rotated within the bearings 4 and 5 of the casting G. 'The mold may, of course, be rotated in either a vertical or a horizontal po- O'r again, reaction might besi tion, but El prefer to use the vertical method of spinning the mold by centrifugalaction because of the high speeds which may readily be secured by this method. The spindle 3 may be rotated by means of the belt wheel 7 secured to the spindle 3,over which a belt 4 driven from any convenient source of power is adapted to be placed, or the spindle 3 may be rotated by an individual drive, as by the direct connection of some prime mover thereto, as is disclosed in applicationof Aylesworth and Aiken No. 495301, filed May 11, 1909, u'pon which U` S. Patent No. 1911948 has been granted. After the material has been placed within the mold l, the

cap S is screwed or otherwise Secured upon the container 2, and 'the charge of aldehyde or other compressed gasdesired is intro:

duced throughpassagewa'y 9 formed in the tube 10, the passageway 9 being provided with a valve 11 for clos-ing the same after the charge of gas has been introduced. The tube 10 may be provided with a counterweighted portion 12, if desirable, to counterbalance the valve 11' during the rotation of the mold. 'The container, the mold and its 'contents may be maintained at the desired temperature by any convenient means as by the burner 13. The record 14 is fol-med on the record surface of the mold l after the ll'by the centrifugal action induced by the high speed of rotation of the mold. During this operation the final reaction .between the ingredients 'of the. composition ensues, changing the same into a no'n-plastic body which, as in the case of the resinized phenol condensation products, may alsob'e insoluble in all ordinary solvents except boiling concentrated sulfuricacid, and also infusible Less time is consumed in the molding operation with the use of high temperatures dur ing the final reaction, 'and also the greater will be the tendency to the evolution ofgases,

necessitating an increase of pressur'e to counteract the same as the temperatures are raised'to lessen the .time factor, Good results are obtained with the use of temperatures above 320degrees F. in the case of the 'resiuized phenol condensatio'n products.

Referring to F ig. 2 of. the drawings, a convenient' form of apparatus for carrying out the above described' processes are here disclosed( Here the mold 1 is placed within the container 2, which is formed integral' with a. spindle in the form of a stepped bearingB'," which may be driven by' any convenient means !as by the belt pulley 7'. The apparatus shown is arranged for a vertical spinning operation, the stepped spin-` .dle 3' being supported `by any convenient means as the balls 14 and .15. The stepped spindle'' is formed with a central passageway into :which is insertedthe end of the stationary pipe 16 by. which the charge of compressedgas may be introduced, the supply of the 'same being-regulated as by means of the valve 11'. The stepped spindle 3' is furnished with a stufiing box 17, which may be filled with any suitable packng material surrounding the stationary pipe 16.' The pipe 18 is inserted within the central aperture through the stepped spindle 3 from above, in the manner illustrated, to rotate with the spindle 3' around the upper the gas from the pipe 16 into the mold 1. The

'pipe 18 may be carriedsome distance 'above the bottomofthe'contaner 2', and furmshed with perforations 19 'for the exit, of the' gas into the mold 1, and with a cap 20 on its' mold.

upper' end to prevent any of the charge of material pipe 18.

As stated, excellent results have been ob-' tained i-n my process with the use of both acid and basic substances as condensing agents Small percentages' of such substances as sodium hydroxid, lithium hy droxid, .metallic oxids, and acid radicals may be usedsuccessfully.

lVhen gelatins or other albuminoids are used, the substance may be soaked in cold water' until it swells,`when the excess of Water is removed. The swelled gelatin is then heated until it melts and is' poured hot into the mold andthe aldehyde added. In the case of formaldehyde solution, the pro- 'porti'ons of the latter may be varied between 'five and twenty per cent. of 40% i solution of formaldehyde. The temperature of the mold is maintained in the case of such ingredients at about 212 degrees F duringthe hardening operation.

This may be done by connecting the mold with a suitable chamber in which a water absorbng substance s contaned. Such substances as quick lme, ZlnC chlord, phos- .phoric anhydrids or anhydrous copper sul- 'ates nay be used forthis' purpose.

In the case of the third specific method of combining the ingredients'described above,

the condensing agentmay be added to a so-v lution containing the 'initial or intermediate reaction product of the ingredients, which has been formed without the aid of a catalytic agent, or this intermediate product may be placed directly in the mold without the aid ofa 'solution and the condensing agent added to the melted substance in the here the condensing agentis added to theingredients dissolved in a volatile solvent as described, I have found good re: sults to accrue from also addng more aldehyde on-methylene containing substance to the solution, preferably in the 'form of paraformaldehyde or other solid aldehyde. I have found excellent results to accrue from I the use of hydrochloric acid vapor or gas as a catalytc agent.

The process has so far been 'described in connection with the molding of cylindrical sound records. It is, ho-wever, obvious that t is also' applcable to' the tormaton of other symmetrical objects of such materials' in which it is desirable that `the vaporization of the ma,ss, wh1ch would otherwise ensue'during the r eaction,-shouldbe counter-- acted. Also the method may be used in the formation of disk sound records by the use `of a rotating mold`such as that described placed in the mold falling into the' and claimed in my application No. 493052 filed April 29, 1909, in which the molds for the disk records are secured' to the periphery of a syminetrical chamber which is rotated about its axis, forcing the recordnaterial which is introduced into the molds into intimate eontactwith the same by centrifugal 'force and thus tforming the record. Of course, it is ohrious also that other objects besides disk sound records might easilyhe manufactured in the same manner.

Having now described my invention, what I claim and desire to protect by Letters Patent is as follows: i

1. The method of molding sound records and other objects ot' substances non-plastic in their linal condition, consisting in introducing into a suitable rotatable mold ingredients which react to t'orm substances which in their final stage are non-plastic at such temperatures as may be employed without injury to the substance or mold, subjecting the substance in the mold to gaseous pressure, causing the final reaction between the ingredients to ensue in the mold, and at the same'time while niaintaining the gas-A eous pressure revolving the mold at a high rate ot'speed to spread the substance uniformly over the niold surface and alsoto counteract the tension of'dissociation in the substance during its reaction by centrit'ugal. force, and continuing the operation until the final non-plastic cast is toi-med, substantially as described.

The method of molding sound records' and other objects of substances non-plastic in their final condition consisting in'heating a revolublenold containing influid condition substances which react on application of heat to form. substances which in their final stage are non-plastic at such temper- `atures as may he en'ployedwithout -1nu-ry to the substance or mold, subje'cting the substance in the mold to gaseous pressure and at the same trime revolving the mold at a high rate of speed to spread the substance uniformly over the mold surface and also to counteract the tension of dissociation in the substance during its reaction by centrifugali force, and contnung the operation *until the final `non-plastic cast is formed,

substantially as described.

.3. The method ot' molding sound records and other 'objects ot' substa'nces non-plastic in their final condition, consisting in introducing into a suitable rotatable mold a substance which reacts with formaldehyde on application ot' beat to. forn a substance* which in tsfinal stage is non-plastic at such temperatures as may be' employed without inju'y to the substance or molchintroducing into the mold and substance a charge of 'compressed tormaldehyde gas, scaling the mold, applying heat sufficient to cause' the entire reaction to ensue in the* mold and at -cast is formed, substantially as described.

r. The method of molding sound records and other objects of substances non-plastie in their final condition, consisting in introducing into a suitable rotatable mold a substance which reacts with formaldehyde on 'application of heat to form a substance which in its final stage is non-plastic at such injury to the substance or mold, subjecting the substance in the mold to formaldehyde gas under pressure, applying heat sufiicient to cause reaction between the substance in' the mold and the formaldehyde gas to ensue temperatures as may be employed without in the mold and at the same time while' maintaining the gaseous pressure re olving the mold at a high .rateot speed 'to spread the substance uniformly over the mold surface, and continuing the operation until the final non-plastic cast is formed, substantally as described.

The method of molding sound records I and other objects of substances non-plastic jin their final condition, consisting in introducing into a suitable rotatable mold a substance'whch reacts with an aldehyde on application of heat to form a substance which in its final stage is non-plas'tc at such tem-` peratu-res as may be employed without injury to the substance oi' mold, introducing into the mold and substance a charge ot' an aldehyde gas under pressure, scaling 'the mold, applying -heat suflicient to cause the entire reaction 'to ensue in the mold -and at the same time revolving the mold at a high rate of speed to spread the substance uniformly over the mold surface, and continuing the operation until'the final non-pl'astic cast-is formed,'substantially as described;

6. The' method of molding 'sound records and other objects ot' substances hon-plastic in their final condition, consisting in introducing into a suitable rotatable mold a substance which re'acts with a substance containing the methylene 'radical on application of heat to form a substance which -in its final stage is non-plastic at such temperatures as may he employed without injury to the substance or mold, introducing into the mold and substance a charge of compressed gas of a substance containing the methylene .radicah scaling the: mold, applying heat suflicent to ause the entire reaction to ensue in the mold and at the same time revolving the mold at'a. high rate of speed to spread the substance`uniformly over the mold surface, and continuing the operation until the final non-plastic cast is fol-med, substantially as described.

7. The method of molcling sound records and other obj'ects of-substances non-plastc in their finalcondition, consisting in intro-- ducing into a suitable rotatable mold a substance'which reacts with 'an aldehyde on application of heat t'o for-m'a substance which in its' 'finalstage is non-plastic at such temperatures as may be employed without inju'ry to the substance or inold, subjecting the substance in' the mold to an aldehyde gas under pressure, applying 'heat suflicient to cause reaction between the substance inthe mold and the aldehyde gas to ensue in the `mold, ndat the same time while maintaining th'e gaseous pressure revolving the vdients which harden by` Chemical action on application of suflicient heat to form a substance which in its final stage is non-plastic, subjecting the ingredients in the mold to gaseous pressure and heat'suflicient to cause the final reaction and at the same time revolving the mold at a high rate of speedto spread the substan'ce uniformly over the mold surface and also to counteractthe tension of dissociation in the substance during its reacton by centrfugal force, and continuing the operation until the final nonplastic cast is formed, substantia-lly as described.

9. The method of molding sound records and other'objects of substances non-plastic in their final condition, consisting indntroducing into a suitable rotatable mold a substance which reacts with 'an aldehyde on 'application of heat to form a substance which in, its final stage is non-plastic, subje'cting 'the mass in the niold, with which is incorporated a condensing agent, to a charge of.an aldehyde gas under pressure and to he'at suflicient to cause reaotion between the mass in themold and the aldehyde gas and at the same time revolvng the inold at a 'high rate of speed to spread the substance uniformly 'over the mold surface, and continuing the .operation until the final nonplastic cast is formed, substantially as described'.

10'. The method of molding sound records and other objects of substances non-plastic in their final condition, consisting in introducing into a suitable rotatablemold a phenol and a condensing agent land subjecting the mass in the mold to a charge of an aldehyde gas under p-ressure and to heart sufiicient to cause the final rea'ction .and at the same time revolving the mold at ahigh rate of speed to spread the substance uniformly over the mold surface, and continuing the operation until the final non-plastic cast'i's formed, substantially as described.

'This i specification signed and Witnessed this 28th day of April, 1909) JONAS W. AYL'SWORTH.

Witnesses:

DYER SMITH, JOHN M. CANFIELD. 

